Installation, Operation, Parts & Service Manual
Contents
1. 4 Oven Temperature Too Low Remed Thaw completely according to instructions Use thermometer to check accuracy of dial indicator Remed Mold retarded product to manufacturers specifications Proof at proper temperature humidity and time Remed Thaw properly in plastic bags to avoid formation of crusting Maintain proper humidity moisture and temperature levels in proofer cabinet Use oven thermometer to insure that dial indicator is accurate Remed Thaw properly in plastic bags keep refrigerated to control aging Proof at proper temperature humidity and time See Above Use oven thermometer to insure correct calibration of oven dial PROBLEM Streaking or Spotting on Crust White Possible Causes 1 Overproofed Remed Make sure correct proofing practices are followed Do not put wet dough into oven for baking Water will serve as insulator preventing even coloration of curst These white spots are referred to as fish eyes PROBLEM Streaking or spotting on Crust Dark Possible Causes 1 Formulation Remedy Dark spotting can often be caused by incomplete mixing in the processing stage of the dough 6 of 11 Dough Age and Characteristics Young Dough Underproofed Has the tendency to develop blisters and blemishes during handling The loaf may often be small in volume have a shell top and a fox red color Always remember the relationship of heat to the2. Your Solutions Partner MODEL PFB PROOFER BASE Installation Operation Parts amp Service Manual 319558F CONTENTS Page SPECIFICATIONS 3 GENERAL PROOFING INFORMATION 3 4 FROZEN DOUGH PROBLEMS CAUSES amp REMEDIES LACK OF VOLUME TOP MUCH VOLUME CRUST COLOR TOO PALE CRUST COLOR TOO DARK CRUST TOO THICK POOR CRUMB TEXTURE CRUMBLY STREAKING OR SPOTTING ON CRUST WHITE STREAKING OR SPOTTING ON CRUST DARK DOUGH AGE AND CHARACTERISTICS YOUNG DOUGH UNDERPROOFED PROPERLY PROOFED GENERAL COMMENTS OLD DOUGH OVERPROOFED DIAGNOSTICS REPLACEMENT PARTS BAKING CENTER CONTROLS 10 WIRING DIAGRAM 11 OO tA OO Co N N NOTICE Please supply the Model Number and the Serial Number when ordering replacement parts or requesting service We recommend service by Duke Authorized Service Agencies during and after the warranty period 2 of 11 Specifications Power to the proofer base is supplied through a nine foot 9 power cord 3 wire 14 gauge equipped with a NEMA 5 15 CAP grounded plug The master on off switch connects to the axial fan thermometer transformer 120v primary 12v secondary and to the controller which has a temperature range from 85 165 F The controller provides power to the air heat element 10 5 watts and to the proofer ready light A second 500 watt element used to regulate humidity in the cabinet is controlled by an infinite switch The humidity e
3. en temperature against temperature dial Recalibrate dial if necessary Rotate inventory Use First In First Out system Use products with earliest date codes first Maintain uniform freezer temperature at minus 10 F Do not Refreeze Thawed dough Place frozen dough in freezer immediately on receipt Retard product in sealed plastic bags Increase moisture humidity setting in proof box Remed Proof at proper temperature humidity and time Use oven thermometer to check accuracy of dial indicator Use proper sized pan or decrease size of dough Remold dough into proper shape as outlined in manufacturers directions and let rise again Remed Retard dough in properly controlled retarding cabinet 38 40 F Keep dough pieces in plastic bag while thawing maintain proper humidity steam or moisture in proof box Maintain proper temperature and humidity levels check water reservoir Use oven thermometer to check accuracy of dial indicator PROBLEM Crust Color is Too Dark Possible Causes 1 Dough Improperly Thawed 2 Oven Temperature Too High PROBLEM Crust Blisters Possible Causes 1 Careless Molding 2 Overproofing PROBLEM Crust Too Thick Possible Causes 1 Dough Has Aged Too Much After Thawing 2 Crust Develops During Proofing 3 Oven Temperature Too Low PROBLEM Poor Crumb Texture Crumbly Possible Causes 1 Dough Has Aged Too Much 2 Overfroofed 3 Proof Box Temperature Too High
4. formed loaf Young dough generates its own internal heat during fermentation A frozen loaf in the retarder and or proofer sees heat only from the outside of the loaf The interior may be 35 38 F at the beginning of the proofing cycle Premature processing of frozen dough will often result in coring or a loaf or roll with an under baked center NOTE The shorter the retarding time the longer the necessary proofing time Cell Structure The cell structure of young dough is nearly circular The cell wall is thin and has little resistance to elasticity This inelasticity often causes the loaf to burst Shelf Life and Texture Young dough has a short shelf life and stales quickly The texture of the baked loaf will be slightly crumbly Properly Proofed Cell Structure The cell structure of correctly proofed dough has an elliptical elongated cell structure and thin cell walls The dough is readily extensible and holds gases easily Shelf Life and Texture Correctly proofed dough will yield the best product having long shelf life uniform crumb and enhanced flavor General Comments 95 of all baking problems are caused by incorrect proofing or retarding 95 of the fermentation in frozen dough occurs during proofing The longer the fermentation stage in dough development the shorter the shelf life The larger the item the lower the proofing temperature Properly proofed pan breads will exhibit break and shred This should be subtle in cha
5. lement will come on only when the air heat element is on The humidity element heats a pan of water in the bottom of the oven producing steam vapor A sixty minute timer controls the timed proof cycle and connects power to a buzzer indicating the end of the cycle There are two probes within the proofer cavity One is connected to the controller to sense oven temperature The second probe is connected to the digital thermometer to indicate oven temperature The axial fan located in the bottom of the oven circulates heated air throughout the cavity The fan runs continuously when the main on off switch is turned on Opening or closing the door has no effect on the heat or fan controls General Proofing Information Today many bakers use frozen dough products in their operations Frozen doughs are ready for traying thawing proofing if required baking and finishing The baker bypasses mixing dividing make up and fermentation time Handling Frozen Dough Frozen dough must be kept at a temperature of 10 F with minimal fluctuations to prevent product damage Be sure to rotate your inventory so that the first product stocked is the first product to be used Frozen dough is affected by three factors Time temperature and humidity Time and temperature are easily controlled with properly maintained equipment Correct proofer humidity control can only be maintained with a balance between temperature and humidity settings Reta
6. on For the best results in a frozen dough operation a relative humidity of 7096 7596 is desirable with a temperature between 90 110 F The humidity and temperatures settings will vary depending on the strength and kind of dough to be proofed 3 of 11 Larger pieces of dough should be proofed at a lower temperature while smaller pieces are proofed at a higher temperature Basic yeast dough should be at room temperature when it is placed in the proofer Placing retarded dough directly from the walk in or refrigerator into the proofer cabinet will often result in excessive build up of condensation on the surface of the dough This may lead to crust imperfections spotting and streaking and blistering In severe cases this may often result in total collapse of the baked product after removal from the oven It is important to stage your retarded product into the proofer to avoid overproofing For optimal results the product must be baked immediately after the proofing process The majority of yeast raised products can be proofed successfully between 90 HOT and 70 75 relative humidity The quality of your final product will depend on the initial product quality and handling from the freezer to the oven Proofing Bagels The proofing process allows the bagels to warm up and to expand slightly before they are boiled Bagels which are not proofed sufficiently may not rise to the surface when they are boiled Howeve
7. r overproofed bagels will tend to collapse after boiling and before they are placed in the oven Optimum temperatures and times will vary for various bagel formulations All bagels should be proofed at a low relative humidity 65 75 R H Bagels which have been held overnight in a retarder or for a short time in a freezer are usually allowed to proof at lower temperatures 86 90 F than bagels processed without interruption Continuously produced bagels are generally proofed at 104 110 F 4 of 11 Frozen Dough Problems Causes amp Remedies Bread amp Rolls PROBLEM lack of Volume Too Small Possible Causes 1 Incomplete Thawing 2 Loaves Too Small for Pan 3 Underproofed 4 Oven Temperature Too High 5 Dough Too Old 6 Dough Has Been Thawed and Refrozen 7 Dough is Dry PROBLEM Too Much Volume Too Large Possible Causes 1 Over Proofing 2 Oven Temperature Too Low 3 Loaves Too Large for Pans 4 Dough Has Risen Too Much During Proofing PROBLEM Crust Color is Pale Too Light Possible Causes Thawing Time Too Long Dough Has Aged 2 Crust Has Developed on Dough 3 Insufficient Humidity in Proof Box 4 Oven Temperature Too Low Remed Thaw completely or allow to proof longer The colder the dough the longer the necessary proofing time Use proper sized pans or increase size of dough Proof at proper temperature humidity and time Use oven thermometer to check ov
8. racter The break should occur directly above the lip of the pan and the shredding slightly above the break This is the result of oven spring Oven spring occurs within the first 10 12 minutes of the bake Old Dough Overproofed As dough ages it becomes more acidic The finished baked loaf has a lighter crust color as a result of the sugar that is depleted through the fermentation process Cell Structure The cell structure of old dough is elliptical in form and has thick cell walls The dough is difficult to form The presence of old cell structure is usually most noticeable in the top or crown of the loaf 7 of 11 DIAGNOSTICS Equipment Problem Remedy Proofer will not operate Make sure cord is plugged in and wall circuit breaker is turned on Check power to master switch at black wire 1 amp white wire 2 If power is present turn switch on and read voltage across wires 3 amp 4 If no voltage is present replace switch Proofer on no fan Read voltage across wires 4 amp 12 going to fan motor If voltage is present replace fan motor Proofer on no heat Check power across wires 5 amp 7 at air heat element If voltage is present replace element If no voltage is present read voltage from wire 7 on element to ground if no voltage check the controller Amber light will illuminate if controller is working Humidity feature not working Humidity element energized only when controller is calling for heat
9. rder Principles Retarders provide a location for the frozen dough to thaw slowly until it reaches a state of even temperature throughout the dough piece Retarders protect the dough from the unequal thawing caused by excessively warm locations The best retarders are designed to promote a controlled cool slightly moist environment To eliminate moisture loss and crusting it is often still appropriate to cover the entire pan of trayed product with a heavy plastic bag NOTE Condensation can cause thin close fitting plastic bags like trash bags to stick to the dough This often creates damaged surfaces when the plastic is pulled free Baking supply houses carry zippered elephant bags specifically for the retarding process By keeping the dough between 33 40 F the yeast activity in the dough is minimal yet limited fermentation does occur improving product flavor and dough handling characteristics Doughs held in the retarder for over 48 hours often will develop strong sour aromas and flavors and if baked will result in inferior crumb texture and shelf life Follow and understand the practices outlined on the following pages when retarding your frozen product 1 Maintain temperature between 33 40 F 2 Avoid formation of crust or skin on dough pieces 3 Retard 12 16 hours overnight 4 Do not over retard product sour product 5 Longer retards will require shorter proof times 6 Fermentation begins Proofer Operati
10. to air element Turn infinite control on Verify voltage across L1 amp L2 of infinite switch Read voltage across H1 amp H2 of infinite switch if not present replace infinite switch If voltage is present check voltage at humidity element at wires 6 amp 13 If voltage is present replace humidity element Thermostat out of calibration Check proofer temperature with remote test instrument Loosen screw to controller knob turn knob to dial setting that agrees with test instrument reading Tighten screw 8 of 11 on Diagram ona 11 12 13 14 15 19 REPLACEMENT PARTS Part 314350 314351 312559 312429 312428 553925 312074 312568 312566 312574 312573 512289 153203 600304 153142 153211 00924 316535 314861 9 of 11 Description Caster w brake Caster w o brake Fan axial Heater humidity 500 watts Heater air 1045 watts Buzzer Infinite switch Thermostat Transformer Thermometer w probe Probe Power switch Heat light Kit Timer Replacement 120V 60Hz Knob Power Cord Door assembly Wire rack Control overlay Baking Center Controls 10 of 11 SCHEMATIC DIAGRAM FOR MODELS 1 amp PFB 2 PROOFER 120 VAG 1 PH HZ TEMPERATURE COMTRGL PROBE TEMPERATUPE SPLAT PROBE JUEL HHE 23 POWER CORD 14 3 FT BLAN 5 15 CAP n A GROUND CONTROL PANEL PART NG 502 724 11 of 11
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